Reinforcing insert for convertible vehicle
TECHNICAL FIELD 
     This invention relates to a reinforcing insert for a convertible type vehicle to provide strengthening of the vehicle body. 
     BACKGROUND ART 
     Convertible type vehicles unlike sedan and hardtop vehicles do not have any rigid roof for providing strengthening of the vehicle body in cooperation with the vehicle floor pan. As such, the vehicle body floor pan has to be sufficiently strong to carry the forces that are normally carried by the roof of sedan and hardtop type vehicles. 
     Relatively recent production convertible type vehicles are made with the same vehicle body floor pan as similar sedan and hardtop type vehicles for purposes of economy. The roof of the vehicle is either removed or the vehicle is constructed with a &#34;dummy&#34; roof that can be recirculated through the vehicle body assembly line to provide support between the vehicle windshield header and the rear deck panel of the vehicle during the vehicle body assembly operation. Since the same floor pan is utilized as with sedan and hardtop type vehicles, reinforcement of the floor pan is necessary in order to have the requisite strength for carrying the forces that the roof would otherwise carry. 
     The David L. Draper U.S. Pat. Nos. 4,457,555; 4,514,891; and 4,570,321 disclose reinforcement of convertible type vehicle body floor pans by a stamped metal center member of an inverted U shape secured to the vehicle body along the central transmission tunnel. A forward section secured to a front end of the center member is attached to the vehicle floor pan at its front end, while a rearward section secured to a rear end of the center member is attached to the vehicle floor pan at its rear end. Between the forward and rearward sections, the center member extends only along the central transmission tunnel of the floor pan and thus does not provide any direct support at lateral extremities of the floor pan adjacent the side door openings of the associated convertible vehicle. 
     DISCLOSURE OF INVENTION 
     This invention provides an improved reinforcing insert for a convertible type vehicle including an occupant compartment having front and rear extremities and side door openings between these extremities. The reinforcing insert is molded from plastic and has a shell-like construction received within the occupant compartment. The reinforcing insert has a front end including a foot portion and also has a rear end of an upwardly and forwardly opening shape. An intermediate portion of the insert includes a floor that extends between its front and rear ends and has side edges for positioning adjacent the side door openings of the vehicle. 
     Provision of the reinforcing insert permits the convertible vehicle to utilize a vehicle body construction that would otherwise be usable only with a sedan or hardtop vehicle reinforced by a hard roof that is not present with a soft top convertible vehicle. 
     In the preferred construction, the reinforcing insert is made by resin transfer molding wherein glass fibers are initially inserted into a mold prior to closing whereupon injection of synthetic resin into the mold provides the molded plastic insert that reinforces the convertible vehicle. This molded plastic reinforcing insert is most preferably constructed as a pair of insert members having a central connection to each other along a longitudinal direction with respect to the vehicle. Such a construction facilitates the molding and also facilitates assembly of the insert within the occupant compartment of the convertible vehicle. In addition to the longitudinally extending central connection, the reinforcing insert also preferably includes ribs for providing strength and connection locations of the reinforcing insert to the convertible vehicle. These ribs, like the central connection, are disclosed as extending longitudinally with respect to the vehicle. However, it should be appreciated that the ribs can also extend laterally with respect to the vehicle as well as longitudinally. Likewise, other formations can also be utilized to provide connection locations of the insert to the vehicle with the rest of the insert spaced from the vehicle. 
     In its preferred construction, the reinforcing insert also includes rear quarter panels that are located to the rear of the side door openings of the convertible vehicle extending upwardly from the floor. These rear quarter panels of the reinforcing insert have upper edges extending rearwardly from the side door openings and secured to the convertible vehicle to provide reinforcement. A trunk ceiling portion of the reinforcing insert extends between the rear quarter panels thereof to define a ceiling of a trunk storage compartment of the convertible vehicle. 
     The rear quarter panels of the preferred construction of the reinforcing insert also preferably include holes that provide a preferred means for mounting a soft top frame of the convertible vehicle and for mounting rear quarter windows thereof at locations to the rear of the side door openings. 
     Adhesive bonds are preferably provided to secure the ribs, the floor side edges, and the upper edges of the rear quarter panels to the convertible vehicle as well as securing the insert members to each other. 
     The objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best mode for carrying out the invention when taken in connection with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     FIG. 1 is an exploded perspective view of a convertible vehicle and a reinforcing insert used therewith according to the present invention; 
     FIG. 2 is a cross-sectional view through the convertible vehicle with the reinforcing insert assembled thereto and is taken generally along the direction of line 2--2 in FIG. 1; 
     FIG. 3 is also a cross-sectional view through the convertible vehicle with the reinforcing insert assembled thereto and is taken along the direction of line 3--3 in FIG. 1; and 
     FIG. 4 is a partial perspective view taken from the side and the rear at an upper location with respect to the convertible vehicle to illustrate the closed condition of the soft top thereof covering the occupant compartment in which the reinforcing insert is assembled. 
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     With reference to FIG. 1 of the drawings, a convertible vehicle generally indicated by 10 includes a vehicle body 12 having an occupant compartment 14 into which a reinforcing insert 16 according to the present invention is inserted and assembled as is hereinafter more fully described. The vehicle body 12 of the convertible vehicle has a conventional construction including left and right front and rear quarter panels 18 and 20 which are respectively located on opposite sides of an engine compartment panel 22 and a rear trunk panel 24. At the rear extremities of the front quarter panels 18 and the engine compartment panel 22, the vehicle body includes laterally spaced windshield pillars 26 that project upwardly and are connected by a windshield header 28 to cooperate therewith in extending around the windshield 30 in a conventional fashion adjacent the front end of occupant compartment 14. Adjacent a rear end of the occupant compartment 14, the trunk panel 24 is located above a trunk storage compartment 32 and is supported in a conventional manner for movement between open and closed positions. Intermediate the front and rear quarter panels 18 and 20, each side of the vehicle has a side door opening 34 that is opened and closed by an associated side door 36. A rocker structure 38 defines the lower extremity of the side door opening 34 and extends between the front and rear quarter panels 18 and 20 on opposite sides of the vehicle floor pan 40 which is also illustrated in FIGS. 2 and 3. 
     As shown in FIG. 4, the vehicle 10 includes conventional side door windows 42 and rear quarter windows 44 that are mounted by suitable unshown regulators for movement between lower open positions and the upper closed positions illustrated. A soft top 46 of the vehicle has a frame 48 that moves the soft top between the closed position shown and an unshown storage position that opens the occupant compartment in accordance with conventional movement of convertible tops. The frame 48 includes a pair of side rails 50 having rear ends that are supported for movement on the vehicle and having front ends that are connected by a convertible top header 52 that is supported by the windshield header 28 shown in FIG. 1 when the convertible top is in the closed position illustrated in FIG. 4. 
     With reference to FIG. 1, the reinforcing insert 16 is molded from plastic and is most preferably provided by resin transfer molding. Such resin transfer moldings are made by a plastic preform and/or glass fibers that are either woven into cloth or sprayed as a mat for insertion into the open mold prior to mold closing, whereupon transfer of liquid synthetic resin into the closed mold and subsequent cooling provides the resin transfer molding. The plastic molded reinforcing insert has a front end 54 including a foot portion 56 and also has a rear end 58 of an upwardly and forwardly opening shape. An intermediate portion 60 of the insert 16 includes a floor 62 that extends between the front and rear ends and has side edges 64 for positioning adjacent the side door openings 34 in the assembled condition. 
     With combined reference to FIGS. 1, 2 and 3, the reinforcing insert 16 preferably includes a pair of insert members 66 having a central connection 68 to each other along a longitudinal direction with respect to the convertible vehicle. More specifically, the central connection 68 is located along the vehicle transmission tunnel 70 of the floor pan 40 at a laterally intermediate location with respect to the laterally spaced rocker structures 38 shown in FIG. 2 and the laterally spaced rear quarter panels 20 shown in FIG. 3. It should, of course, be appreciated that the reinforcing insert can be used with front wheel drive convertible vehicles, that do not have the type of transmission tunnel shown, as well as being used with rear wheel drive cars having such transmission tunnels. 
     As best illustrated in FIGS. 2 and 3, the reinforcing insert 16 includes ribs 72 for providing strength and connection locations of the reinforcing insert to the convertible vehicle. These reinforcing ribs 72 preferably extend longitudinally with respect to the vehicle and project in a downward direction as illustrated in FIGS. 2 and 3 with adhesive bonds 74 providing connections thereof to the floor pan 40. Each insert member 66 has an inclined portion 76 that extends upwardly at the transmission tunnel 70 and has adhesive bonds 78 for providing connections to the transmission tunnel. At the upper ends of the inclined portions 76, each insert has a horizontal portion 80 that overlaps with the horizontal portion of the other insert member with an adhesive bond 82 providing a connection between these portions and an adhesive bond 84 providing connection of the overlapped horizontal portions to the transmission tunnel 70 of floor pan 40. 
     At the lateral outboard sides of the reinforcing insert adjacent the rocker structures 38 as illustrated in FIG. 2, each insert member 66 has its associated side edge 64 provided with an adhesive bond 85 that provides a connection to the rocker structure 38. Thus, this bonding of the side edges 64 cooperates with the other adhesive bonds to integrate the reinforcing insert 16 as a structural component of the convertible vehicle with which it is utilized. 
     With combined reference to FIGS. 1 and 3, the reinforcing insert 16 has its rear end 58 provided with rear quarter panels 86 that are located to the rear of the side door openings 36 (FIG. 1) of the convertible vehicle extending upwardly from the floor 62 provided by each insert member. At the lower ends of the rear quarter panels, the floor side edges 64 have adhesive bonds 90 to lower ends of associated rear quarter panel inner members 88. Rear quarter panels 86 of the reinforcing insert also have upper edges 92 that extend rearwardly from the side door openings and have adhesive bonds 94 for providing connection thereof to the upper ends of the adjacent rear quarter panel inner members 88 of the vehicle body. 
     Any suitable type of adhesive such as polyurethanes and epoxies can be used for the adhesive bonds between the reinforcing insert and the convertible vehicle. Such adhesive bonds are used at all points of contact to provide the reinforcement. Thus the front and rear ends 54 and 58 shown in FIG. 1 also have adhesive bonds at each location of contact with the vehicle. Furthermore, other formations than the illustrated longitudinal ribs can be used to space the rest of the insert from the vehicle as well as providing connection locations for the preferred securement by adhesive bonds. For example, lateral ribs can be utilized as can spot type formations spaced both longitudinally and laterally from each other. 
     As illustrated in FIG. 1, the reinforcing insert 16 also includes a trunk ceiling portion 96 that extends between the rear quarter panels 86 to define a ceiling for the trunk storage compartment 32 and to also define a tray for storage of the soft top with the occupant compartment open to the environment. 
     With continuing reference to FIG. 1, holes 98 in the rear quarter panel 86 provide a preferred means for permitting mounting the rear ends of the side rails 50 of the soft top frame 48 shown in FIG. 4. These rear quarter panels 86 of the insert shown in FIG. 1 also include holes 100 that provide a preferred means for permitting mounting the rear quarter windows 44 illustrated in FIG. 4 at the rear of the side door openings 34. Both the frame and window mountings can be either directly on the reinforcing insert or through the insert to the adjacent vehicle surface as may be most suitable for the particular convertible vehicle. 
     While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs an embodiments for practicing the invention as defined by the following claims.